XSive torture

[LoHo]

A year and a half ago my XS developed a no-spark condition. The usual suspects were addressed without regaining spark. Further fooling around eventually resulted in success and joy, only to turn to sorrow when a strange new tapping sound turned out to be a lost screw having found its way into the #3 cylinder. This prompted a head removal, some cleaning up of the damaged area, new valve seals while the head was off, and reconstruction. Anticipation reverts into sorrow as...no spark.

Today, being a nice day, I turned on the ball game and began going through the connections again, cleaning, spraying, etc. I decided to put the freshly charged battery on and give her a spin. Shock and dismay...SPARK! She tried to start, but I knew the gas was mostly old and the carbs must be ugly.

I took off the carbs (they were ugly) and did a disassemble/clean/reassemble with hope in my heart. Got the floats moving freely, the green gunk out of 1 and 2, sprayed cleaner and compressed air through everything, and put her back together,

No spark.

Not really seeking any advice, just venting a little.

[skids]

Kill switch?
Tipover switch?
Ballast resistor grounding to tank or frame?
Ground strap engine to frame?
Ignition fuse?
Does it crank fast when trying to start?
Check the plug wire pairs to each coil?
Check impulses supplied to coils while cranking? I don't know how to do it but I am sure there is a way.
Any other problems with lights or other electrical?
Swap out a black box as a test?

[BA80]

I gotta ask..................how in the world did a screw get into a cylinder.

[Keithh]

You have my sympathy - mine does that as well. Currently it is running, but tomorrow for no reason, it may not! I'm hoping this last round of cleaning connections, recrimping wires, etc. has finally sorted it out. I have my doubts!

Good luck!

Keith

[BA80]

Kill switch?
Tipover switch?
Ballast resistor grounding to tank or frame?
Ground strap engine to frame?
Ignition fuse?
Does it crank fast when trying to start?
Check the plug wire pairs to each coil?
Check impulses supplied to coils while cranking? I don't know how to do it but I am sure there is a way.
Any other problems with lights or other electrical?
Swap out a black box as a test?

All of the above.

I had a similar problem a couple years ago and it was a ground connection at the four ground wires that come out of the wiring harness and attach at, or near, the rear mounting bolt for the voltage regulator

[LoHo]

It's the randomness that's getting to me. Why did it work for a few minutes then not after I cleaned the carbs?

The screw: I was cleaning/checking the stop switch and as I was putting it back together I dropped the unit and swiped at it with my hand, knocking the hell out of it. The tiny screw I'd been inserting flew off somewhere, but I didn't see it or hear it hit. In my garage, a lost screw is not a novelty, so I got another from a donor pile. I must have swished that tiny spark plug opening, which was empty as I checked plugs and wires. I posted a thread and some picks about a year ago, like this:

[mikubuilder]

had the same thing happen to my VW Jetta

how did you fix it? put a spare head on it?

[bikerphil]

I decided to put the freshly charged battery on and give her a spin. Shock and dismay...SPARK!

I'd try charging the battery again, maybe it's not holding good enough to fire the TCI, JAT

[LoHo]

Naw, I just Dremeled off the rough spots, as I saw little profit in putting expensive parts on a bike with no spark. If I ever figure it out and later I have problems with #3 cylinder, I might replace the head. Until I have some promise of a working bike, what she has will have to do. I have a new tire to put on as well, and might do that just to show some sort of progress.

[LoHo]

It's a new battery, but I may do that just for kicks.

[BA80]

It's the randomness that's getting to me. Why did it work for a few minutes then not after I cleaned the carbs?

The screw: I was cleaning/checking the stop switch and as I was putting it back together I dropped the unit and swiped at it with my hand, knocking the hell out of it. The tiny screw I'd been inserting flew off somewhere, but I didn't see it or hear it hit. In my garage, a lost screw is not a novelty, so I got another from a donor pile. I must have swished that tiny spark plug opening, which was empty as I checked plugs and wires. I posted a thread and some picks about a year ago, like this:

LOL.....the crazy thing is you could stand back at the same distance and TRY all day to hit that spark plug hole with a screw and never get it done.

[LoHo]

Yeah, of course I worried that it may have gone in one of the spark plug holes, but no noise? 14mm hole from three feet or so? C'mon, at least I could have called "glass!" I've kicked myself for not fishing around, but I don't know if I would have found it at that. I guess I'm just lucky...